Dual-action disposable clamp

ABSTRACT

Disclosed is a clamp that includes a mechanical fastener, an expander including a bulbing portion and a shank wherein the bulbing portion of the expander forms a flange by movement of the mechanical fastener without applying an initial clamping force. After formation, the flange is then drawn into a clamping position by continued movement of the mechanical fastener. Also disclosed is a method of using the disclosed clamp.

This application is a continuation of U.S. Utility patent application Ser. No. 12/418,673, filed on Apr. 6, 2009 which will issue as U.S. Pat. No. 8,608,417 on Dec. 17, 2013, which is a continuation of U.S. Utility patent application Ser. No. 12/098,857, filed on Apr. 7, 2008, which is a continuation in part of U.S. Utility patent application Ser. No. 11/973,278, filed on Oct. 5, 2007, application Ser. No. 11/973,278 claims the benefit of U.S. Provisional Application No. 60/849,515, filed on Oct. 5, 2006; U.S. Provisional Application No. 60/857,700, filed on Nov. 8, 2006; and U.S. Provisional Application No. 60/901,171, filed on Feb. 13, 2007, which are each hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to a temporary fastener, and more specifically to a temporary clamp.

BACKGROUND OF THE INVENTION

Modern aircraft are manufactured from numerous panels and other parts that are fastened together with rivets, screws, bolts, and other permanent fasteners. To aid in assembly, parts are typically held together with temporary clamps and fixtures until permanent fasteners can be installed. Parts that incorporate sealant on the mating surfaces require that the temporary clamps exert sufficient force to squeeze excessive sealant from the joint while pulling parts together before the sealant fully cures. Heavy structures fastened with five-sixteenths of an inch size permanent fasteners, for example, require in excess of 500 pounds clamp load to squeeze the sealant out to an acceptable thickness and hold the components together. Other applications, such as in wing-to-body joints, require upwards of 1500 pounds with five-sixteenths of an inch size fasteners to temporarily secure components. The clamp load requirements for other sizes are generally proportional to the cross-sectional area of the basic fastener diameter.

Blind hole clamps are desirable for airframe assembly, because their installation and removal can be more easily automated than the installation and removal of conventional bolts and nuts. However, existing blind hole clamps do not have a blind head large enough to avoid surface damage on the blind side panel when high clamp loads are imparted.

Oftentimes, one or more work pieces are joined with clamps to maintain part orientation during an autoclave curing cycle. Threaded-type reusable blind clamps are capable of high clamp loads, but lack the smooth shank needed to avoid clogging with resin as the parts are cured. As a result, the clamps are difficult to remove and may damage the work pieces upon removal. Blind tack rivets may have the required smooth shank but are incapable of imparting sufficient clamp load to maintain parts in the required orientation. Conventional slave bolts are not capable of automated installation and removal.

In addition, threaded temporary blind clamps are easily clogged with sealant and resins, making removal from assemblies difficult and necessitating cleaning before they may be reused. Another problem with threaded temporary fasteners is that they protrude above the accessible panel surface by a relatively large amount. Accordingly, robotic assembly equipment must retract or back away from the work pieces to avoid collisions with installed clamps. As a result, installation of threaded temporary fasteners requires additional time to traverse from one location to another.

Finally, the clamping capability of threaded temporary clamps is limited, because the blind head is discontinuous and high clamp loads result in surface damage to the work pieces. Temporary blind tack rivets have a low profile but must be removed by drilling through the manufactured head. Drilling through the head, however, generates metal chips that can damage panel surfaces. Oftentimes, for example, the rivet spins in the hole during the drilling operation, halting the advance of the drill bit through the tack rivet and prolonging the removal cycle time. Tack rivets also have very low clamp loads and produce a small blind-side upset that is not suitable for use in laminated composite panels.

Slave bolts may consist of a conventional nut and bolt or a pull-type lock bolt with a swage collar. Slave bolts may provide a non-clogging shank, non-drill out removal and high clamp loads. However, slave bolts require access to both sides of the work pieces and, in many cases, two operators to install. Two-sided installations are difficult and costly to automate.

Therefore, a need exists for a clamp, or a temporary fastener, having a smooth cylindrical shank without grooves, threads and other discontinuities that may become clogged with sealant or cured resin and which is capable of high clamp loads (greater than 500 pounds for a five-sixteenths of an inch size clamp) without damaging fragile panel surfaces. In addition, a need exists for a low profile temporary clamping fastener capable of installation and removal from a single accessible side of the work pieces, preferably by robotic equipment, in a manner that does not generate drilling debris. A one-sided installation and removal process is desired for saving labor costs over a conventional two-person operation using nuts and bolts. Finally, a need exists for a temporary fastener having a predetermined geometry to control installation clamp loads rather than allowing the installation force to be controlled by outside influences, such as, operator skill.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A, 1B and 1C illustrate a side elevational view, a perspective view, and a cross-sectional view along line A-A of a clamp in an embodiment of the present invention.

FIGS. 2A, 2B and 2C illustrate a side elevational view, a cross-sectional view along line B-B, and a perspective view of the clamp of FIGS. 1A-1C at least partially installed in a work piece in an embodiment of the present invention.

FIGS. 3A, 3B and 3C illustrate a side elevational view, a cross-sectional view along line C-C, and a perspective view of the clamp of FIGS. 1A-1C in an installed condition in an embodiment of the present invention.

FIGS. 4A and 4B illustrate a side elevational view and a cross-sectional view along line D-D of a clamp having a clutch nut in an embodiment of the present invention.

FIGS. 5A and 5B illustrate a side elevational view and a cross-sectional view along line E-E of the clamp of FIGS. 4A and 4B with a wrenching tool engaged in an embodiment of the present invention.

FIGS. 6A and 6B illustrate a side elevational view and a cross-sectional view along line F-F of the clamp of FIGS. 4A and 4B with a wrenching tool engaged where the clamp may be removed from the work piece in an embodiment of the present invention.

FIG. 7 illustrates a power tool engaged with the clamp of FIGS. 3A through 3C in an embodiment of the present invention.

FIG. 8 shows a representative perspective view of an un-crimped expander component in an embodiment of the present invention.

FIG. 9 shows a representative perspective view of an expander component as crimped in an embodiment of the present invention.

FIG. 10 shows a representative perspective view of an expander component as partially formed in an embodiment of the present invention.

FIG. 11 shows a representative perspective view of an expander component as completely formed in an embodiment of the present invention.

FIG. 12 illustrates a graph of a predictable load curve of an expander in an embodiment of the present invention.

FIGS. 13A and 13B illustrate a side elevational view and a cross-sectional view along line G-G of an alternative embodiment of a clamp.

FIG. 13C illustrates a portion of the cross-sectional view of FIG. 13B.

FIGS. 14A and 14B illustrate a side elevational view and a cross-sectional view along line I-I of the clamp of FIGS. 13A and 13B partially installed in a work piece.

FIGS. 15A and 15B illustrate a side elevational view and a cross sectional view along line J-J of the clamp in FIGS. 13A and 13B partially installed in a work piece.

FIGS. 16A and 16B illustrate a side elevational view and a cross-sectional view along line K-K of the clamp in FIGS. 13A and 13B in an installed condition in a work piece.

FIGS. 17A and 17B illustrate a side elevational view and a cross-sectional view along line L-L of the clamp of FIGS. 13A and 13B where the clamp may be removed from the work piece.

FIG. 18 illustrates an exploded view of several components of one embodiment of the clamp of FIGS. 13A and 13B after removal from the work piece.

FIG. 19 illustrates a side elevational view one embodiment of a bolt component of a clamp as described herein.

FIG. 20 illustrates a top plan view of a shift washer component of a clamp described herein.

FIG. 21 illustrates a side elevational view of the shift washer illustrated in FIG. 20.

FIG. 22 illustrates an exploded view of an alternative embodiment of the shift washer, thrust washer and spacer components used in one embodiment of a clamp described herein.

FIG. 23 illustrates a cross-sectional view of an uncrimped expander component of a clamp described herein.

FIG. 24 illustrates a cross-sectional view of an crimped expander component of a clamp described herein.

FIG. 25 illustrates a side elevational view of a shank used in an embodiment of a clamp described herein.

DETAILED DESCRIPTION OF THE DRAWINGS

For the purpose of promoting an understanding of the disclosure, reference will now be made to certain embodiments thereof and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure is thereby intended, such alterations, further modifications and further applications of the principles described herein being contemplated as would normally occur to one skilled in the art to which the disclosure relates. In several FIGs., where there are the same or similar elements, those elements are designated with similar reference numerals.

Disclosed herein is a deformable sleeve that can be incorporated in a blind side fastener that is deformable from a shape that fits through an aperture to a flanged shape that provides a clamping surface around the aperture the sleeve previously passed through. The terms “bulb,” “bulbed,” and “bulbing” are used herein to describe the deformation process and the result of that process where the outer diameter of the deformable sleeve swells upon application of a compressive load that buckles the deformable sleeve in a predetermined fashion to form the desired flanged shape.

Also related to the formation of the flange, the term “non-canted” is used to describe the transition between the axial surface of the sleeve that is not deformed and the deformed portion of the sleeve that creates a substantially perpendicular surface of the flange that clamps against the blind surface of the work pieces. The term “non-canted” refers to the portion of the flange covering the work piece around the aperture not being part of the transition between the flange surface and the axial sleeve surface, thereby avoiding stress concentrations at the edge of the aperture through the work piece.

Referring now to the drawings, and in particular to FIGS. 1A-3C, a clamp 10 is illustrated generally comprising: a core bolt 14 in threaded engagement with an expander 12, a shank 16, a spacer 18 and a thrust washer 21. Core bolt 14 includes externally threaded portion 17 and head portion 19. Core bolt 14 is a mechanical fastener and externally threaded portion 17 is a securing portion of mechanical fastener 14. Expander 12 includes first end 22, second end 23, bulbing portion 25, positioned between first and second ends 22 and 23, and internally threaded portion 20. The expander 12 is positioned at a first end of the core bolt 14 such that the core bolt 14 is movable through the expander 12. Specifically, applying torque to the core bolt 14 drives the core bolt 14 through the expander 12. The core bolt 14 may have wrenching portions 8 that are sized and shaped to be rotated by, for example, a wrenching tool. In one embodiment, the expander 12 is internally threaded and is in meshing threaded engagement with external threads 17 of the core bolt 14.

In a preferred embodiment, a first break groove 24 is positioned at a second end of the core bolt 14, opposite the expander 12. A second break groove 26 is positioned between the first break groove 24 and the first end of the core bolt 14. The first break groove 24 and the second break groove 26 may be weakened portions of the core bolt 14 that fail at predetermined torque or compression loads. In one embodiment as shown in FIGS. 1B and 3B, second break groove 26 is a notch around the circumference of core bolt 14. In another embodiment, as shown in FIG. 2B, second break groove 26 is a dog-bone shaped narrowing of core bolt 14. These embodiments of second break groove 26 are discussed in greater detail below.

In an exemplary embodiment, the first break groove 24 is sized to fail prior to the second break groove 26, as shown in FIGS. 3A-3C. For example, at a torque sufficient to clamp work pieces 30 a, 30 b together a desired amount, the first break groove 24 fractures and a portion of the core bolt 14 is severed. The second break groove 26 will remain intact until it is desired to remove the core bolt 14 from the work pieces 30 a, 30 b. To do so, additional torque may be provided on the core bolt 14 to fracture the core bolt 14 at the second break groove 26.

A shank 16 may be positioned between the first end of the core bolt 14 and the expander 12. In a preferred embodiment, the expander 12 may be rotationally keyed to the shank 16 such that rotation of the shank 16 rotates the expander 12, as shown in FIGS. 1A-1C. The threaded core bolt 14 slides inside the shank 16 along the length of the core bolt 14. As torque is applied to the core bolt 14, the core bolt 14 rotates in the shank 16 and threads into the expander 12 as shown in FIGS. 2A-3C. The core bolt 14 moves through the expander 12 causing the expander 12 to bulb or to expand to a size in which the expander 12 has a larger diameter than the diameter of the shank 16 and the diameter of the hole in the work pieces.

The shank 16 has a flange 28 extending outward from the outer diameter of the shank 16. The flange 28 may be an enlarged portion extending in a direction perpendicular to the axis of the shank 16. In a preferred embodiment, the flange 28 is integrally formed with the shank 16. The flange 28 may be sized such that the flange 28 limits the amount of the load that may be induced into the expander 12. At a predetermined axial load, the flange 28 shears loose from the shank 16 and allows the shank 16 to move into bore 31 of the spacer 18.

A spacer 18 may be positioned at an end of the shank 16. In an embodiment, the spacer 18 engages a flange 28 of the shank 16 and may prevent rotation of the shank 16 when torque is applied to the core bolt 14. The spacer 18 may have wrenching flats 40 for engagement with wrenching tools, for example, a tool to prevent rotation of the spacer 18. The spacer 18 may have a bore 31 in which the core bolt 14 may extend there through.

A boss 29 may extend from an end of the shank 16 opposite the expander 12. The spacer 18 may be positioned at an end of the shank 16 adjacent the boss 29. The bore 31 of the spacer 18 may be an interference fit with the boss 29 of the shank 16 such that the shank 16 is rotationally restrained. The boss 29 of the shank 16 extends into and frictionally fits within the spacer 18. In an embodiment, the boss 29 and the bore 31 in the spacer 18 are non-circular to rotationally key the shank 16 and the spacer 18 together. For example, the bore 31 and the boss 29 may have corresponding shapes such that relative rotation is prevented. The spacer 18 may be positioned such that the underside of the spacer 18 abuts the flange 28 of the shank 16.

A washer 21 may be positioned between the spacer 18 and an end of the core bolt 14. In one embodiment, the washer 21 may be a thrust washer or other type of resilient element to spread the compressive stresses over a larger area than without the washer 21. Bearing surfaces 80 of the core bolt 14 may bear against a top side 82 of the washer 21, as best illustrated in FIGS. 3B. In another embodiment, the washer 21 may be bowed to act as a spring washer, for example, to maintain compressive loads on the work pieces 30 a, 30 b.

The clamp 10 may be installed by an automated process or by automated equipment, such as robotic equipment. For example, after inserting the clamp 10 into aligned apertures in the work pieces 30 a, 30 b, a tool 100 may engage the spacer 18 and the wrenching surfaces 40 of the spacer 18. In one embodiment, the clamp 10 may be inserted into a top surface 30 c of the work piece 30 a and may extend through to a blind side 30 d of the work piece 30 b with expander 12 spaced apart from blind surface 37 as illustrated in FIG. 2A. In one embodiment, the tool 100 (see FIG. 7) may have a first component 56 for rotationally restraining the spacer 18, which, in turn, prevents the shank 16 from rotating as illustrated in FIG. 7. The tool 100 may have a second component (such as tool 52 illustrated in FIGS. 5B and 6B and described below) to provide torque to the core bolt 14 to move core bolt 14.

In alternative embodiments, the tool 100 may be used by or incorporated into robotic or other automated equipment to thread the core bolt 14 into the expander 12 and cause the expander 12 to bulb or otherwise enlarge while being spaced apart from blind surface 37 so that the flange is formed without exerting an initial clamping load on work pieces 30 a and 30 b. Once the expander 12 is fully bulbed, as shown in an embodiment in FIGS. 3A-3C, the compressive load on the shank 16 increases until the flange 28 on the shank 16 shears loose at a predetermined compressive load. In one embodiment, the flange 28 shears at a compressive load of 1000 pounds for a five-sixteenths inch size fastener. Continued rotation of the core bolt 14 causes the shank 16, with the expander 12 attached, to translate into the spacer 18 until the expander 12 contacts the far side of the work pieces 30 a, 30 b. When the flange 28 shears loose, the torque required to drive the core bolt 14 may drop to a negligible amount or nearly zero, but the torque required to drive the core bolt 14 may increase as the expander 12 contacts and clamps the work pieces 30 a, 30 b together.

The installation of the clamp 10 may be controlled by controlling the installation torque, or by use of the first break groove 24. For example, when the torsion required to continue rotating the core bolt 14 exceeds the strength of the first break groove 24, a portion 15 of the core bolt 14 severs as shown in FIGS. 3A-3C. To facilitate removal of the clamp 10, the tool 100 may be applied to the core bolt 14 to apply torque and rotate the core bolt 14. At a predetermined amount of torque, the second break groove 26 fails and the spacer 18, the washer 21, and the shank 16 are discarded from the accessible-side of the work pieces 30 a, 30 b. The expander 12 and remaining portion of the core bolt 14 may be pushed through the work pieces 30 a, 30 b and discarded or otherwise moved through the work pieces 30 a, 30 b.

Advantageously, the tool 100 may be used to both install and to remove the clamp 10. To this end, the clamp 10 may effectively be used as a temporary fastener for clamping panels and other objects together. In addition, drilling to remove the clamp 10 is eliminated. Accordingly, the damage caused by off-center drilling and the generation of metal chips caused by drilling are eliminated.

In addition, the bulbing nature of the expander 12 ensures that clamp loads are spread over a relatively large area to avoid damaging the work pieces 30 a, 30 b. The pre-bulbed geometry of the expander 12 ensures that the apertures of the work pieces 30 a, 30 b do not become rounded or otherwise damaged. In an embodiment, the expander 12 may have a flanged end 32, as illustrated in FIGS. 8-11, which show expander 12 in four different stages. FIG. 8 shows expander 12 as manufactured prior to the flanged end 32 being crimped or swaged inwardly by mechanical treatment during manufacture as best shown in FIG. 9. In a preferred embodiment, the expander 12 may have a thicker-walled leading edge 50 that resists buckling and a thin-walled bulbing region bounded on one end by transition portion 34 which has a diameter slightly less than the hole diameter in the work pieces 30 a, 30 b. This arrangement results in a sharp, non-canted transition 36 between leading edge 35 and outer edge 33 such that edge interference between an aperture rim and outer edge 33 or leading edge 35 is avoided, as illustrated in FIGS. 10 and 11. FIG. 12 illustrates a predicted load curve with bulbing of the expander 12 indicated at approximately eight hundred pounds for a five-sixteenths size clamp. Of course, the clamp 10 may be modified to change the load in which bulbing occurs as will be appreciated by one of ordinary skill in the art.

Advantageously, the clamp 10 avoids clogging with resins and sealants due to the cylindrical and smooth shape of the shank 16. The design, shape and size of the clamp 10 allows incorporation of the clamp 10 into many applications where known rivets and clamps are not suitable, such as, in use with composite material cured in autoclave.

The grip range of the clamp 10 may correspond to or may be controlled by the length of the spacer 18. For example, the spacer 18 may have a length sufficient to receive the shank 16 after the flange 28 shears loose. A low profile for efficient robotic applications is possible by limiting the grip range. For example, a five-sixteenths of an inch size clamp having a three-eighths inch gripping range may have an installed protrusion approximately one inch above the accessible-side of the work pieces 30 a, 30 b.

In another embodiment, the clamp 10 has a nut 60 that is at least partially engaged with the core bolt 14 as illustrated in FIGS. 4A-6B. In such an embodiment, the core bolt 14 may be threaded from the end adjacent the expander 12 to the wrenching portions 8. Accordingly, the nut 60 may be in threaded engagement with the core bolt 14. The nut 60 may be, for example, cylindrical and internally-threaded. In one embodiment, the nut 60 may be positioned between the thrust washer 21 and the head portion 19 of core bolt 14. Upon installation, the nut 60 may freely rotate with the core bolt 14 and may act as an extension of a head portion 19 of the core bolt 14.

Referring to FIGS. 5A and 5B, tool 51 is illustrated. Tool 51 comprises inner tool 52 and outer tool 54. Outer tool 54 comprises cylindrical bore 55 with one-way clutch 57 and hex insert 58 press fit inside cylindrical bore 55. Inner tool 52 includes wrenching surfaces or a one-way clutch, as appropriate; to rotate wrenching portions 8 on core bolt 14. One-way clutch 57, as shown, is engaged with outer surface 41 of nut 60. Hex-insert 58, as shown, is engaged with wrenching flats 40 on spacer 18.

During removal of the clamp 10, as illustrated in FIGS. 6A and 6B, the nut 60 may be fixed and prevented from rotation by, for example, one-way clutch 57. An outer surface 41 of the nut 60, for example, may be engaged by a one-way clutch, a roller-type clutch or other structure that allows rotation of the nut 60 during installation but prevents rotation of the nut 60 when the core bolt 14 is rotated in the removal direction. Upon removal, the core bolt 14 unthreads from the nut 60 and the expander 12. The expander 12 may remain keyed to the shank 16 which remains keyed to the spacer 18.

In such an embodiment, the first break groove 24 may be incorporated into the clamp 10 and may be dependent upon whether the clamp 10 is configured for installation with torque-controlled tools. The second break groove 26 may be absent in this embodiment since removal may be accomplished by unthreading the core bolt 14 from the assembly, rather than fracturing the core bolt 14 to separate components of the clamp 10. Of course, the first break groove 24 and the second break groove 26 may be incorporated in such an embodiment as will be appreciated by one of ordinary skill in the art.

Referring now to FIGS. 13A-18, clamp 110 is illustrated in several embodiments. Clamp 110 includes core bolt 114, thrust washer 121, spacer 118, shift washer 128, shank 116 and expander 112. Core bolt 114 is a mechanical fastener.

As shown in FIGS. 13A, 13B and 13C, core bolt 114 comprises bolt head 107 including wrenching portions 108, top portion 107 a, bottom portion 107 b and first weakened region 124. Core bolt 114 also includes second weakened region 126 and threaded portion 117. Shift washer 128 includes shear segment 129 and weakened regions 125. In some embodiments, shift washer 128 and/or thrust washer 121 act as a spring washer to maintain compressive loads in clamp 110. Shank 116 includes boss 115, shoulder 109 and key receptacle 113 b and expander 112 includes key 113 a. Spacer 118 includes bore 131, wrenching flats 140 and recesses 119 on the top and bottom of spacer 118.

Clamp 110 shares several similar features with clamp 10 described above but also includes several differences. In particular, it should be noted that first weakened region 124 differs from first break groove 24 in that first weakened region 124 includes longer area of minimum diameter as compared to first break groove 24. As will be discussed below, either weakened region 124 or first break groove 24 may be used in any of the embodiments illustrated herein. Similarly, second weakened region 126 also includes an elongated portion having a reduced diameter as compared with second break groove 26 as shown in FIGS. 1B and 3B.

Another difference between clamp 110 and clamp 10 is that flange 28 of clamp 10 is essentially replaced by shift washer 128 in clamp 110. While flange 28 is disclosed as integral with shank 16, shift washer 128 is separate from shank 116. In either embodiment, flange 28 or shift washer 128 serves as a means to prevent shank 16 or shank 116 from translating into bore 31 or bore 131 of spacer 18 or spacer 118 until after expander 12 or expander 112 has substantially completed bulbed, as described herein. In yet another embodiment (not illustrated), shift washer 128 is incorporated with spacer 118 as a unitary structure which also serves as a means to prevent shank 16 or shank 116 from translating into bore 31 or bore 131 of spacer 18 or spacer 118 until after expander 12 or expander 112 has substantially completed bulbed.

Clamp 110 is configured with thrust washer 121 adjacent to bottom portion 107 b and partially in recess 119 on the top of spacer 118 with shift washer 128 partially in recess 119 on the bottom of spacer 118. The recess 119 on the bottom of spacer 118 and/or shift washer 128 may optionally include knurling or other friction enhancers or mechanical interlocks at the interface between these components as are known in the art to reduce relative rotation between spacer 118 and shift washer 128.

Boss 115 passes through the center of shift washer 128 with shoulder 109 on shank 116 abutting shift washer 128 against shear segment 129 over core bolt 114. Boss 115, shoulder 109 and/or shift washer 128 may optionally include knurling or other friction enhancers or mechanical interlocks at the interface between these components as are known in the art to reduce relative rotation between shift washer 128 and shank 116. Expander 112 abuts shank 116 on threaded portion 117 of core bolt 114. Shank 116 and expander 112 are rotationally restrained together by key 113 a positioned in key receptacle 113 b. In alternative embodiments, other methods known to those skilled in the art may be used to rotationally restrain shank 116 and expander 112 together over core bolt 114.

Recesses 119 in spacer 118 serve to center thrust washer 121 and shift washer 128 over bore 131. Boss 115 serves to center bolt 114 in the middle of shift washer 128. Similarly, thrust washer 121 centers bolt 114. Thrust washer 121, shift washer 128 and boss 115 in combination serve to center bolt 114 in the middle of bore 131. Such centering serves to ensure shoulder 109 is aligned with shear segment 129 and bore 131 to permit passage of shank 116 though bore 131 as described herein. It has been found that accurately aligning shank 116, shift washer 128 and bore 131 decreases variances in the force required to separate shear segment 129 from shift washer 128 as described below.

As assembled as shown in FIGS. 13A, 13B and 13C, clamp 110 may include some amount of preload to hold the individual components of clamp 110 together and to permit friction to prevent relative rotation of some components. For example, it may be beneficial for shank 116, shift washer 128 and spacer 118 to be held together so that it will be possible to secure shank 116 from revolving by restraining wrenching flats 140.

Bore 131 through spacer 118 may optionally include longitudinal knurling or other irregularities to reduce rotation of shank 116 as it progress through spacer 118 as described below.

Referring to FIGS. 14A and 14B, clamp 110 is illustrated partially installed through work pieces 130 a and 130 b. Work piece 130 a includes aperture 131 a and front side aperture rim 132 a while work piece 130 b includes aperture 131 b, blind surface 133 and blind side aperture rim 132 b.

As illustrated in FIGS. 14A and 14B, clamp 110 includes bulbed expander 112′. Bulbing expander 112 into bulbed expander 112′ is the first stage of installation of clamp 110. After inserting clamp 110 through aperture 131 a and 131 b, expander 112 is bulbed to form bulb expander 112′ by restraining wrenching flats 140 while rotating wrenching portion 108 to revolve core bolt 114 and threaded portion 117 with respect to shank 116 and expander 112. As expander 112 advances along threaded portion 117, shank 116 restrains the top portion of expander 112 while the bottom portion of expander 112 continues to advance along threaded portion 117 of core bolt 114. This exerts a compression force on expander 112, causing expander 112 to deform into bulbed expander 112′ including flange 111. In one embodiment, flange 111 extends substantially perpendicular to the axis of shank 116 and the remaining portions of expander 112 forming a substantial flange to engage blind side aperture rim 132 b with substantially uniform pressure. Similarly, in one embodiment, shift washer 128 provides uniform clamping force against front side aperture rim 132 a. In the illustrated embodiment, shift washer 128 is substantially flat, however, other embodiments are contemplated wherein shift washer 128 is whatever shape is required to uniformly engage front side aperture rim 132 a. In alternative embodiments, additional washers or other structures/supports may be located on or around shank 116 and adjacent to shift washer 128 to permit the use of clamp 110 with irregular geometries, such as countersunk apertures (not illustrated).

FIGS. 14A and 14B, illustrated expander 112 fully bulbed with shift washer 128 intact and shear segment 129 attached to shift washer 128. This permits flange 111 and bulb expander 112′ to be substantially fully formed prior to drawing work pieces 130 a and 130 b together. Further tightening of shaft 114 as illustrated in FIG. 14 b results in shear segment 129 separating from shift washer 128 permitting shank 116 to advance into spacer 118 as shown in the following figures. Accordingly, in the illustrated embodiment, the compressive/torsion forces required to bulb expander 112 are less than the force required to fracture shear segment 129 from shear washer 128 or first weakened region 124 or second weakened region 126.

FIGS. 15A and 15B illustrate shank 116 partially advanced into spacer 118 with shear segment 129 separated from shift washer 128′ and positioned above shank 116. FIGS. 15 a and 15 b illustrate clamp 110 prior to drawing work pieces 130 a and 130 b together but after shear segment 129 has separated from shift washer 128′.

Referring now to FIGS. 16A and 16B, clamp 110 is illustrated fully installed with work pieces 130 a and 130 b clamped together with flange 111 abutting blind side aperture rim 132 b and shear segment 128′ abutting front side aperture rim 132 a. Shank 116 and shear segment 129 fill the majority of the length 118D of spacer 118. Also, first weakened region 124 on bolt head 107 has fractured, separating bolt head 107 into top portion 107 a and bottom portion 107 b, with bottom portion 107 b continuing to abut and restrain thrust washer 121.

Referring to FIGS. 17A and 17B, clamp 110 is illustrated in the process of being removed from work pieces 130 a and 130 b. Specifically, weakened region 126 has fractured due to continued rotation of core bolt 114 from the position illustrated in FIGS. 16A and 16B such that second weakened region 126 has failed separating core bolt 114 from threaded portion 117. As illustrated, expander 112′ is connected to threaded portion 117 and available for removal from the blind side of work piece 130 b while the remaining portions of core bolt 114, shank 116, thrust washer 121, spacer 118, shear segment 129 and shift washer 128′ are available for removal from the front side of work piece 130 a.

As should be apparent from the above description of FIGS. 13-17, the failure point of four different components needs to be controlled so that installation occurs as described. First, expander 112 should substantially fully bulb prior to any other component fracturing. Next, shear segment 129 should shear off shift washer 128 prior to the first or second weakened regions 124 and 126 failing. Next, first weakened regions 124 should fracture prior to second weakened region 126, allowing top portion 107 a to be removed, indicating clamp 110 is installed. Finally, second weakened region 126 fractures, severing the internal connections clamping work pieces 130 a and 130 b together and permitting the removal of the various components of claim 110 from work pieces 130 a and 130 b.

Referring now to FIG. 18, several of the components of clamp 110 are illustrated after removal from work piece 130 a and 130 b including core bolt 114, thrust washer 121, shear segment 129, spacer 118 including shank 116, shift washer 128′, bulbed expander 112′ and threaded portion 117.

Referring to FIG. 19, one embodiment of core bolt 114 is illustrated in greater detail, in particular, first weakened region 124 is shown having length 124L representing the linear length of the narrowed diameter of first weakened region 124. Similarly, second weakened region 126 is illustrated having a length 126L representing the length of the portion having a narrowed diameter in second weakened region 126. These embodiment may reduce the amount of energy released when first and second weakened regions 124 and 126 fracture as compared to other embodiments disclosed utilizing notched break grooves.

In this regard, in some applications it may be undesirable to release a substantial amount of energy when fracturing threaded portion 117 from the rest of core bolt 114. Such energy could be release in the form of kinetic energy imparted to the various components of clamp 110. While portions located on the front side of work piece 130 a are likely restrained by the tool used to fracture clamp 110, no similar structure would restrain the portions located on the blind side of work piece 130 b. It is possible for components such as threaded portion 117 and bulbed expander 112′ to be ejected from aperture 131 b with sufficient velocity to damage other components that may be located in their path.

Conversely, a brittle type fracture of first weakened region 124 may be desirable to generate a distinct failure indicator with fewer rotations of bolt head 108. And many embodiments will have a tool engaged with top portion 107 a when first weakened region 124 is fractured that could absorb any imparted kinetic energy, potentially mitigating top portion 107 a as a projectile.

The particular embodiment selected for a particular bolt 114 or 14 depends upon the particular application and material used for bolt 114 or 14. Providing a longer narrowed diameter, such as 124L or 126L, may increase the amount of plastic deformation that occurs prior to fracture and may shift the fracture from a brittle type rapid fracture to a ductile type tear with reduced energy release during the tear. One consequence of using weakened regions such as 124 or 126 as compared to break grooves 24 or 26 is a greater number of rotations of bolt 114 or 14 could be required to complete the desired fracture.

In yet other embodiments, a notch type weakened region could be utilized having a radius sufficient to reduce or eliminate any notch type stress concentration factors (not illustrated). In any event, desirable performance characteristic can be achieved in the first and second weakened regions 124 and 126 by balancing bolt material with geometry considerations of the first and second weakened regions 124 and 126, including, but not limited to, minimum diameter, notch effects, length 124L and/or 126L, and/or other stress concentrators or stress relievers.

Referring to FIGS. 20 and 21, one embodiment of shift washer 128 is illustrated including weakened region 125. As illustrated in FIGS. 20 and 21, weakened region 125 is a depression on both the top and bottom of shift washer 128 narrowing the effective thickness of shift washer 128 and also defining shear segment 129. In one embodiment, weakened region 125 may be machined into top and bottom or either the top or the bottom of shear segment 128. In another embodiment, weakened region 125 may be formed by a cold working stamp or embossing operation on the top and/or bottom of shift washer 128. In one embodiment, weakened region 125 is positioned approximately at the outer diameter of shank 116 to permit shank 116 to pass through shift washer 128 after separation of shear segment 129.

With further regard to shift washer 128, it should be understood that weakened regions 125 are optional. It is possible to control the force required to remove shear segment 129 from shift washer 128 by other means such as thickness control. However, weakened region(s) 125 provide one means to artificially modify the strength of stock material that may have varying shear properties. For example, an operator could control the size and/or depth and/or number of weakened region(s) to tailor a stock material to desired shear strength.

Referring now to FIG. 22, alternate embodiments of shift washer 128, spacer 118 and thrust washer 121 are illustrated. In particular, shift washer 128 includes flange 128.5 while thrust washer 121 includes flange 121.5. In the illustrated embodiment, flanges 128.5 and 121.5 are approximately the same dimension and each are sized to fit in recesses 118.5 located on the top and bottom of spacer 118. The embodiment illustrated at FIG. 22 permits spacer 118 to be installed in either direction, potentially reducing assembly error.

Referring now to FIGS. 23 and 24, an embodiment of expander 112 is illustrated as expander 112 a. In FIG. 23, expander 112 a is illustrated before any crimping or swaged as discussed above with regard to mechanically treating expander 12. As illustrated, expander 112 a includes threaded portion 156, thin-walled bulbing region 152, transition 154, flanged end 132, leading edge 150 and key 113 a. Thin-walled bulbing region 152 is defined by tapered wall portion 155 and thin-walled portion 153 between tapered wall portion 155 and transition 154. The portion of expander 112 a around threaded portion 156 is sufficiently thick to resist buckling under the compressive load used to deform thin-walled bulbing region 152. As shown in FIG. 23, diameter 132D of flanged end 132 is greater than diameter 112D of expander 112 a prior to being crimped or swaged as described above. In the illustrated embodiment, leading edge 150 and flange end 132 have sufficient wall thickness to resist buckling due to compressive loads described above.

Referring to FIG. 24, expander 112 b is illustrated after flange end 132 has been crimped or swaged to reduce diameter 132D′ of flanged end 132 to either equal to or less than diameter 112D of expander 112 b. As illustrated in FIG. 24, thin-walled portion 153 is deformed into a frustoconical body between tapered wall portion 155 and transition 154 with transition 154 defining groove 157 on the outer surface of expander 112 b. At its deepest point, groove 157 and transition 154 have an outer diameter of 154D that is smaller than either diameters 112D or 132D′. Thin-walled bulbed region 152 is predisposed to buckle on sufficient compressive load between flanged end 132 and threaded portion 156 to form flange 111. Of note, transition 154 is located inside of the outer diameter 132D′ of flanged end 132 such that the radiused transition formed when thin-walled bulbed region 152 buckles while creating flange 111 during the bulbing of expander 112 b forms a non-canted transition between thin-walled portion 153 on flange 111 and flanged end 132 that will not directly impact or contact blind side aperture rim 132 b because such the radiused transition is located inside of aperture 131 b.

Referring to FIG. 25, an embodiment of shank 116 is illustrated including boss 115, shoulder 109 and key receptacle 113 b. For reference, in the illustrated embodiment, boss 115 extends from the inner diameter of shank 116 and has a wall thickness approximately one-third the wall thickness of shank 116. As described above, boss 115 abuts the inside of shift washer 128 and serves to help center shank 116 over bore 131 of spacer 118.

As should be apparent from the above descriptions, clamp 110 can be installed (and removed) using similar tools described above for use with clamp 10, including manual and automatic processes.

Also as described above with regard to clamp 10, the pre-bulbed geometry of expander 112 helps ensure that blind side aperture rim 132 b does not become rounded or otherwise damaged during clamping. The pre-bulbed geometry can spread clamping forces evenly over a relatively large area to avoid damaging work piece 130 b.

Also, clamp 110 retains the overall cylindrical and smooth shape exhibited by clamp 10, allowing the use of clamp 110 in many applications where other known rivets and clamps are not suitable such as when adhesives may extrude into apertures 130 a and 130 b.

Flange 28 and shift washer 128 are embodiments of a blocking means that prevents the shank from advancing through the space until expander 12 or 112 bulb to form a blind side flange such as flange 111.

It should be understood that “wrenching portions” and “wrenching flats,” as used herein, are intended to accommodate any known surface that can be used to engage a manual or automatic tool, including a cylindrical surface engageable by a one-way clutch or roller clutch. The clamps 10 and 110 disclosed herein can be used in both manual and automated applications. Use of cylindrical surfaces instead of wrenching flats makes it easier to use clamps 10 and 110 with automated installation robots. Conversely, in manual applications, human operators are adapt at adjusting parts as required to fit geometric wrenches, and geometric wrench apparatus are generally less expensive than one-way clutches. So other applications lend themselves to the use of conventional wrenching surfaces.

In one embodiment, the following materials are used for components of clamp 110. Shank 116 is made from 7075-T6 Aluminum (Al) Alloy. Shear Washer 128 is made from 6061-T6 Al Alloy. Spacer 118 is made from 2024-T4 or 7075-T6 Al Alloy. Expander 112 is made from one-quarter hard (17% cold reduced) austenitic stainless steel, such as AISI 304, or spheriodized annealed steel, such as AISI 8740. Core bolt 114 is made from 4130 steel, heat treated to 40-44 on the Rockwell C scale. The preceding embodiment is provided by way of example only. Other materials may be substituted as desired to obtain varying performance from clamp 110. In one embodiment, clamp 10 utilizes the same materials for corresponding components.

While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected. 

I claim:
 1. A clamp for clamping work pieces together through aligned apertures, the work pieces having a front side surface and a blind surface, the clamp comprising: a mechanical fastener comprising a head portion on a proximal end and a distal end; an expander coupled to said mechanical fastener, said expander comprising a first end portion, a second end portion and a bulbing portion positioned therebetween, wherein said bulbing portion is constructed and arranged to bulb outwardly to form a flange with an enlarged outer diameter when said bulbing portion is compressed between said first and second end portions with a first compressive load, wherein said first end portion of said expander is coupled to said mechanical fastener proximate to said distal end of said mechanical fastener and wherein said expander undergoes substantial plastic deformation when the flange is formed; a shank positioned on said mechanical fastener between said second end portion of said expander and said head portion of said mechanical fastener, wherein said mechanical fastener is movable relative to said shank; a spacer positioned on said mechanical fastener constructed and arranged to receive said shank and to permit said shank to move axially through said spacer, wherein said spacer is too large to pass through the aligned apertures; wherein said expander is constructed and arranged to be insertable through the aligned apertures from the front side; wherein said expander is constructed and arranged such that it can be compressed by movement of said mechanical fastener relative to said spacer and said shank to cause said bulbing portion to form a flange without applying an initial clamping force to the work pieces; wherein the formed flange may be drawn into a clamping position against the blind surface to clamp the work pieces together by the continued movement of said mechanical fastener with respect to said spacer; and wherein said clamp is constructed and arranged to be removed from the work pieces by uncoupling said expander from said mechanical fastener and removing said mechanical fastener from the front side of the work pieces without damaging said mechanical fastener.
 2. The clamp of claim 1, further comprising a blocking member that prevents said shank from advancing through said spacer until a second compressive load is exerted that is greater than said first compressive load.
 3. The clamp of claim 2, wherein said blocking member is a flange.
 4. The clamp of claim 2, wherein said blocking member is a shear washer.
 5. The clamp of claim 1, wherein said mechanical fastener comprises a core bolt with an externally threaded portion.
 6. The clamp of claim 5, wherein said expander further comprises an internally threaded portion proximate to said second end portion, wherein said internally threaded portion is in threaded engagement with said externally threaded portion.
 7. The clamp of claim 6, wherein said expander further comprises a transition portion defining a groove in the outer surface of said expander positioned between said first end portion and said bulbing portion that forms a non-canted transition between the flange and said first end portion after said bulbing portion forms the flange.
 8. The clamp of claim 1, further comprising a resilient element constructed and arranged to maintain the load clamping the work pieces together in the event of the work pieces moving closer together due to a sealant squeezing out of a space therebetween.
 9. The clamp of claim 1, further comprising a shear washer positioned between said shank and said spacer that prevents said shank from advancing through said spacer until a second compressive load is exerted that is greater than said first compressive load.
 10. The clamp of claim 9, wherein said shank further comprises a boss constructed and arranged to interface with said shear washer to align said shear washer with respect to said shank, wherein said boss extends inside of a smallest internal dimension of said shear washer.
 11. The clamp of claim 10, wherein said spacer further comprises a recess constructed and arranged to align said shear washer with respect to said spacer.
 12. The clamp of claim 1, further comprising a flange on said shank that prevents said shank from advancing through said spacer until a second compressive load is exerted that is greater than said first compressive load.
 13. The clamp of claim 1, wherein said expander is compressed by rotating said mechanical fastener with respect to said spacer.
 14. The clamp of claim 1, wherein said expander is positioned away from the blind surface when inserted through the aligned apertures.
 15. The clamp of claim 1, wherein said expanding nut, said shank and said spacer are substantially rotationally constrained together.
 16. The clamp of claim 1, wherein said shank and said spacer are constructed and arranged to be removed from the front side of the work pieces with said mechanical fastener without damaging said shank or said spacer.
 17. A method for clamping two work pieces together through aligned apertures, the work pieces having a front side and a blind surface, the method comprising: inserting the clamp of claim 1 into the aligned apertures from the front side so that the mechanical fastener extends through the aligned apertures with the expander spaced apart from the blind surface; moving the mechanical fastener to compress the expander; continued moving the mechanical fastener causing the bulbing portion of the expander to form a flange without applying an initial clamping force to the work pieces; and subsequent to forming the flange, further moving the mechanical fastener thereby clamping the work pieces between the space and the flange.
 18. The method of claim 17, further comprising: compressing a resilient element while clamping the work pieces together, wherein the resilient element is constructed and arranged to maintain the compressive load clamping the work pieces together in the event the work pieces move closer together.
 19. The method of claim 17, further comprising: unthreading the bulbed expander from the mechanical fastener; removing the mechanical fastener and the shank from the aligned apertures; and threading a replacement expander onto the mechanical fastener to form the clamp of claim
 1. 20. A clamp for clamping work pieces together through aligned apertures, the work pieces having a front side surface and a blind surface, the clamp comprising: a mechanical fastener comprising a head portion on a proximal end and a threaded portion on a distal end; an expander comprising a first end portion, a second end portion and a bulbing portion positioned therebetween, wherein said first end portion defines an internally threaded portion threadingly engaged on said mechanical fastener at said threaded portion, wherein said bulbing portion is constructed and arranged to bulb outwardly to form a flange with an enlarged outer diameter when said bulbing portion is compressed between said first and second end portions with a first compressive load, and wherein said expander undergoes significant plastic deformation when the flange is formed; a shank positioned on said mechanical fastener between said second end portion and said head portion, wherein said mechanical fastener is movable relative to said shank; and a spacer positioned on said mechanical fastener constructed and arranged to receive said shank and to permit said shank to move axially through said spacer, wherein said spacer is too large to pass through the aligned apertures; wherein said expander is constructed and arranged to be insertable through the aligned apertures from the front side, wherein said expander is constructed and arranged such that it can be compressed between said first and second end portions by rotation of said mechanical fastener relative to said spacer to cause said bulbing portion to form a flange without applying an initial clamping force to the work pieces; wherein the flange may be drawn into a clamping position against the blind surface to clamp the work pieces together by the continued movement of said mechanical fastener with respect to said spacer; and wherein said expander is constructed and arranged to be removed from said mechanical fastener to remove the clamp by unthreading said mechanical fastener from said expander and removing said mechanical fastener from the front side of the work pieces without damaging said mechanical fastener.
 21. The clamp of claim 20, further comprising a blocking member that prevents said shank from advancing through said spacer until a second compressive load is exerted that is greater than said first compressive load.
 22. The clamp of claim 20, wherein said expander is compressed by rotating said mechanical fastener with respect to said spacer. 